MHG Heating Gassero Alubox 50 User manual

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Installation and Operating Manual for the
Alubox Range 50-2200kW

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Section
Page #
1.0
Appliance TypeThere are three outputs within the Wallcon range
3
1.1
Installation Regulations and Requirements
3
2.0
Appliance Warranties
4
2.1
Supplied Components
4
3.0
Technical Data
5-6
4.0
Dimensions 50-150
7
4.1
Dimensions208-290
8
4.2
Dimensions540-700
9
4.3
Dimensions1000
10
4.1
Installation and Service Clearances
11
5.0
Electrical Connections
12
6.0
Hydraulic Design Single Unit (Option 1)
13
6.1
Hydraulic Design Single Unit (Option 2)
14
6.2
Hydraulic Design Single Unit (Option 3)
15
6.3
Hydraulic Design Single Unit (Option 4)
16
6.4
Hydraulic Design Single Unit (Option 5)
17
6.5
Hydraulic Design Cascade System (Option 6)
18
6.6
Hydraulic Design BMS System (Option 7)
19
7.0
Fluing Options
20
7.1
Balanced Flue Terminal Positions For Boilers Below and Above 70kW Net Input
21
8.0
Filling The System
22
8.1
Expansion Vessel, System Water Quality
23
9.0
Care With The Use of Flux
23
9.1
Boiler Controller
24
10.0
Accessing Controller Parameters
25-52
10.1
Weather Compensation Slope
53
10.2
Controller Error Codes
54-56
10.3
Commissioning The Appliance
57
11.0
Combustion System Commissioning
57-58
11.1
Routine Inspection and Servicing
59
11.2
Routine Service Inspection
59
12.0
Routine Cleaning & Maintenance
59-60
13.0
Troubleshooting
61-62
14.0
Internal Wiring
63
15.0
Spares Diagram
64-65
Notes
66

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1.0 Appliance Type
There are 12 outputs within the large Alubox range.
Please ensure you have the correct unit for the application and where required located correctly within the
cascade prior to beginning the installation.
1.1 Installation Regulations and Requirements
The installation of Alubox boilers must be in accordance with the relevant requirements of Gas Safety
(Installation & Use) Regulations 1994, Health & Safety at Work Act, Building Regulations, IEE Regulations,
and Construction (Design & Management) Regulations 1994, Local Authority Bye-Laws, National, Fire
Regulations and Insurance Company requirements.
The following Codes of Practice are also applicable:-
BS 5440-1: 2000 Installation of flues and ventilation for gas appliances of rated input not exceeding 70 kW net
(1st, 2nd and 3rd family gases).
Part 1: Specification for the installation of flues.
BS 5440-2: 2000 Installation of flues and ventilation for gas appliances of rated input not exceeding 70 kW net
(1st, 2nd and 3rd family gases).
Part 2: Specification for installation and maintenance of ventilation for gas appliances.
BS 5449: 1990 Specification for forced circulation hot water central heating systems for domestic premises.
BS 6644: 2011 Specification for gas fired hot water boilers of rated inputs between 70kW (net) and
1.8MW(net) (2nd and 3rd family gases).
BS 6798: 1987 Specification for installation of gas fired hot water boilers of rated input not exceeding 60 kW.
BS 6880: 1988 Code of Practice for low temperature hot water heating systems of output greater than
45kW.Parts 1, 2 & 3.
BS 6891: 1988 Specification for installation of low pressure gas pipework of up to 28mm (R1) in domestic
premises (2nd family gases)
BS 7593: 1992 Code of Practice for treatment of water in domestic hot water central heating systems.
BS 7671: 1992 Requirements for electrical installations.IEE Wiring Regulations.Sixteenth edition.
CISBE Guide reference sections B7, B11 and B13.
CP342 Part 2: 1974 Code of Practice for centralized hot water supply.
GE/UP/2 Gas installation pipework, boosters and compressors on industrial and commercial premises.
IGE/UP/4 Commissioning of gas fired plant on industrial and commercial premises
IGE/UP/10 Installation of gas appliances in industrial and commercial premises. Part 1: Flued appliances.
And any addition prevailing regulation and or code of practice not detailed above.

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2.0 Appliance Warranties
All MHG appliances enjoy a full 24 month warranty as detailed in our terms and conditions.
The guarantee period shall begin on the day of commissioning, or at latest 3 months after delivery has been
made.
The customer shall only be able to claim against MHG under guarantee if the commissioning of the object of
delivery has been carried out by MHG staff or the authorised supplier, If the customer has followed MHG's
instructions relating to the treatment and maintenance of the object of delivery, and if no replacement parts of
outside origin have been fitted.
Parts subject to wear such as ignition electrodes, seals etc. are strictly excluded from the guarantee.
In addition to the above warranties, the Primary Heat Exchangers, of Aluminum construction, carry a 24 month
guarantee against manufacturing or material defect.
2.1 Supplied Components
All Alubox are supplied with a HWS probe sensor and QAC 34 outside Air Sensor. (To activate direct on boiler
weather compensation)

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3.0 Technical Data

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4.0 Dimensions Alubox 50-150
Label
Connections
F
System Flow –1”
R
System Return –1”
G
Gas Supply –1”
FO
Flue Outlet –Ø100mm
AI
Air Intake –Ø110mm
Con
Condensate Discharge –Ø25mm
50-70
WxDxH
640x582x1049
90-150
WxDxH
640x575x1095

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4.1 Dimensions Alubox 208-290
Label
Connections
F
System Flow –2”
R
System Return –2”
G
Gas Supply –1”
FO
Flue Outlet –Ø200mm
Con
Condensate Discharge –Ø25mm
WxDxH
645x1420x1350

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4.2 Dimensions Alubox 540-700
Label
Connections
F
System Flow –DN80
R
System Return –DN80
G
Gas Supply –DN65
FO
Flue Outlet –Ø250mm
AI
Air Intake –Ø125mm
Con
Condensate Discharge –
Ø25mm
WxDxH
645x1420x1350

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4.3 Dimensions Alubox 1000
Label
Connections
F
System Flow –DN100
R
System Return –DN100
G
Gas Supply –DN65
FO
Flue Outlet –Ø250mm
Con
Condensate Discharge –Ø25mm
WxDxH
890x1970x1590

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4.4 Installation and Service Clearances

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5.0 Electrical Connections
Basic electrical connection for the Alubox range.
The wiring connections of the Alubox boilers are located within a terminal box mounted to the rear of the
boilers case.
All wiring via terminal in connection blocks.
High voltage Wiring terminals
Power in to Boiler
230 Volts - 50 Hertz
Q2 Heating circuit pump
Live, Neutral, Earth, (Max switching 0.5Amp) (Q2)
Can be used as Multifunctional Output
Q3 Hot water charging pump
Live, Neutral, Earth, (Max switching 0.5Amp) (Q3)
Can be used as a Multifunctional Output
*Additional wiring to be added at commissioning if
required.
Additional outputs can be configured if required.
Low Voltage Wiring Terminals
Room Thermostat
Volt Free Enable, Not Polarity Sensitive, Room
stat/BMS ( <24 Volts) (H5)
0-10V enable *
Polarity sensitive, Max 10Volts, To be configured
at Commissioning, (H3)
Outside Air Temperature Sensor
QAC34 sensor provided for direct on boiler
weather compensation. (B9)
Cascade Sensor
QAD36 strap on sensor, provided on request.
Hot Water Enable
Thermostat or Sensor, to be configured at
commissioning, (B3)
Cascade Communication *
To be wired from Master boiler to all slave boilers
in parallel, polarity sensitive.
*Additional wiring to be added at commissioning if
required.
Additional outputs can be configured if required.
* Screened cable must be used for this connection.

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6.0 Hydraulic Design Single Unit (Option 1)
Electrical Connections Single Unit (Option 1)
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump Max 0.5Amp
230Volts-50Hz
Heating Circuit Pump
Output
Q2 Central Heating Pump Max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
Outside Air Sensor
Input
Outside temperature Sensor. QAC34 sensor
provided
**Room Thermostat
Input
Room thermostat, Volt free Enable
<24 Volts
**0-10Volt Enable
Input
0-10Volt Enable H3
0-10Volts
MHG Pressure Manager
Input
Multifunctional to be configured during
commissioning
<24 Volts
**Only one enable to be used per installation. Volt Free or 0-10.

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6.1 Hydraulic Design Single Unit (Option 2)
Electrical Connections Single Unit (Option 2)
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump Max 0.5Amp
230Volts-50Hz
Heating Circuit Pump
Output
Q2 Central Heating Pump Max 0.5Amp
230Volts-50Hz
DHW Pump
Output
Q3DHW Storage Pump Max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
Outside Air Sensor
Input
Outside temperature Sensor. QAC34 sensor
provided
**Room Thermostat
Input
Room thermostat, Volt free Enable
<24 Volts
**0-10Volt Enable
Input
0-10Volt Enable H3
0-10Volts
DHW Demand
Input
Volt free thermostat or sensor
<24Volts
MHG Pressure Manager
Input
Multifunctional to be configured during
commissioning
<24 Volts
**Only one enable to be used per installation. Volt Free or 0-10.

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6.2 Hydraulic Design Single Unit (Option 3)
Electrical Connections Single Unit (Option 3)
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump Max 0.5Amp
230Volts-50Hz
3 Way Valve Open
Output
Additional internal wiring required at
Commissioning
230volts-50Hz
3 Way Valve Close
Output
Additional internal wiring required at
Commissioning
230volts-50Hz
Heating Circuit Pump
Output
Q2 Central Heating Pump Max 0.5Amp
230Volts-50Hz
DHW Pump
Output
Q3DHW Storage Pump Max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
Outside Air Sensor
Input
Outside temperature Sensor. QAC34 sensor
provided
**Room Thermostat
Input
Room thermostat, Volt free Enable
<24 Volts
**0-10Volt Enable
Input
0-10Volt Enable H3
0-10Volts
Mixed Circuit Sensor
Input
Additional internal wiring required at
Commissioning QAD 36 sensor required
<24 Volts
DHW Demand
Input
Volt free thermostat or sensor
<24Volts
MHG Pressure Manager
Input
Multifunctional to be configured during
commissioning
<24 Volts
**Only one enable to be used per installation. Volt Free or 0-10.

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6.3 Hydraulic Design Single Unit (Option 4)
Electrical Connections Cascade System (Option 5)
Master Boiler
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump max 0.5Amp
230Volts-50Hz
Heating Circuit1 Pump
Output
Q2 Central Heating Pump Max 0.5Amp
230Volts-50Hz
DHW Pump
Output
Q3DHW Storage Pump Max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
Cascade Communication
Output
Cascade Module. Screened Cable must be used
Coms
Outside Air Sensor
Input
Outside temperature Sensor. QAC34 sensor
provided
**Room Thermostat HC1
Input
Room thermostat, Volt free Enable
<24 Volts
**0-10Volt Enable HC1
Input
0-10Volt Enable H3
0-10Volts
DHW Demand
Input
Volt free thermostat or sensor
<24Volts
MHG Pressure Manager
Input
Multifunctional to be configured during
commissioning
<24 Volts
**Only one enable to be used per installation. Volt Free or 0-10.
Slave Boiler
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
Cascade Communication
Input
Cascade Module. Screened Cable must be used
Coms

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6.4 Hydraulic Design Single Unit (Option 5)
Electrical Connections Cascade System (Option 5)
Master Boiler
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump max 0.5Amp
230Volts-50Hz
Heating Circuit1 Pump
Output
Q2 Central Heating Pump Max 0.5Amp
230Volts-50Hz
DHW Pump
Output
Q3DHW Storage Pump Max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
Cascade Communication
Output
Cascade Module. Screened Cable must be used
Coms
Outside Air Sensor
Input
Outside temperature Sensor. QAC34 sensor
provided
**Room Thermostat HC1
Input
Room thermostat, Volt free Enable
<24 Volts
**0-10Volt Enable HC1
Input
0-10Volt Enable H3
0-10Volts
Mixed Circuit Sensor
Input
Additional internal wiring required at
Commissioning QAD 36 sensor required
<24 Volts
DHW Demand
Input
Volt free thermostat or sensor
<24Volts
MHG Pressure Manager
Input
Multifunctional to be configured during
commissioning
<24 Volts
**Only one enable to be used per installation. Volt Free or 0-10.
Slave Boiler
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
Cascade Communication
Input
Cascade Module. Screened Cable must be used
Coms

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6.5 Hydraulic Design Single Unit (Option 6)
Electrical Connections BMS System (Option 6)
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
**Room Thermostat HC1
Input
Room thermostat, Volt free Enable
<24 Volts
**0-10Volt Enable HC1
Input
0-10Volt Enable H3
0-10Volts
**Only one enable to be used per installation. Volt Free or 0-10.

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6.6 Hydraulic Design Single Unit (Option 7)
Electrical Connections BMS System (Option 7)
Master and Slave boilers require the following wiring
High Voltage
Input/Output
Terminal Description/Label
Type
Mains power
Input
Brown=Live, Blue=Neutral, Yellow/Green=Earth
230Volts-50Hz
External Boiler Pump
Output
Q1 Boiler Circulation Pump max 0.5Amp
230Volts-50Hz
Low Voltage
Input/Output
Terminal Description/Label
Type
**Room Thermostat HC1
Input
Room thermostat, Volt free Enable
<24 Volts
**0-10Volt Enable HC1
Input
0-10Volt Enable H3
0-10Volts
**Only one enable to be used per installation. Volt Free or 0-10.
Master Boiler Additional Wiring connections
Low Voltage
Input/Output
Terminal Description
Type
Communication Connection
to Slave boiler
Output
Cascade Communication
Comms
Screened cable
Common flow sensor
Input
Cascade flow sensor
Screened cable

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7.0 Fluing Options
Flue Type
Description
B23
Open Flued Installation with products of combustion
flued through a wall or roof to outside. Combustion
air taken from the room via adequate ventilation.